Carrier WEATHERMASTER Z8075 105 User Manual

48ZG,ZN030-105  
48ZT,ZW,Z6,Z8075-105  
Gas Heating/Electric Cooling Units  
with COMFORTLINK™ Controls  
User’s Information Manual  
NOTE TO INSTALLER:  
TO LIGHT UNIT  
This manual should be left with the equipment owner.  
1. Do not turn off the electrical power to unit without  
first turning off the gas supply.  
2. Before attempting to start the gas heating section,  
familiarize yourself with all the procedures that must  
be followed.  
WARNING: If the information in this  
manual is not followed exactly, a fire or  
explosion may result causing property  
damage, personal injury or loss of life.  
— Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
— WHAT TO DO IF YOU SMELL GAS  
• Do not try to light any appliance.  
3. Never attempt to manually light the unit with a match,  
lighter, or any other flame. If the electric sparking de-  
vice fails to light the burners, refer to the shutdown  
procedures, then call your dealer as soon as possible.  
If you do not follow these instructions exactly, a fire or  
explosion may result, causing property damage, injury, or  
loss of life.  
• Do not touch any electrical switch;  
do not use any phone in your  
building.  
• Immediately call your gas supplier  
from a neighbor’s phone. Follow the  
gas supplier’s instructions.  
See Fig. 1 for location of gas valve(s). Refer to Fig. 2 while  
proceeding with the following steps.  
1. Turn off the unit demand for cooling or heating by using  
the scrolling marquee. The scrolling marquee is located in  
the control box at the compressor end of the unit.  
• If you cannot reach your gas sup-  
plier, call the fire department.  
ESCAPE  
a. Push the  
is shown.  
key unit a blank display screen  
— Installation and service must be per-  
formed by a qualified installer, service  
agency or the gas supplier.  
b. Push the  
lit.  
key until the SERVICE TEST LED is  
ENTER  
c. Push the  
STOP.  
key. The display will show  
key again. The NO/YES display  
key to toggle the display to  
ENTER  
d. Push the  
will flash.  
Improper installation, adjustment, alteration, service, or  
maintenance can cause injury or property damage. Refer to  
this manual. For assistance or additional information, con-  
sult a qualified installer, service agency, or the gas supplier.  
e. Push the  
or  
ENTER  
YES and then push  
. The unit will be  
locked off from heating, cooling or any operation.  
The controls will still function and the display will  
still operate.  
2. Close the field-installed manual gas shutoff valve.  
Before performing recommended maintenance, be sure  
main power switch to unit is turned off. Electrical shock  
could cause personal injury.  
3. Turn off the electrical power to the unit using the optional  
disconnect or the field-installed disconnect and lock off  
using proper lockout and tag-out procedures.  
Your combination heating/cooling rooftop unit is equipped  
with an automatic direct spark ignition system and induced-  
draft power combustion blower.  
4. Open the burner section hinged access door.  
5. Move the switch on the gas valves to the OFF position  
and wait 5 minutes.  
NOTE: If this is the first installation of the unit, the gas  
flue hoods must be installed before operating unit. These  
must be installed for the unit to run properly.  
Do not attempt to light by hand; personal injury may result.  
6. Move the switch on the gas valves to the ON position.  
7. Close the burner section hinged access door.  
8. Turn on the electrical supply to the units.  
9. Open the field-installed manual gas valve.  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 04-53480045-01 Printed in U.S.A. Form 48Z-5SO Pg 1 7-07 Replaces: 48Z-3SO  
Book 1  
Tab 1a  
MAIN  
MODE  
Run Status  
Service Test  
Temperature  
ON  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
OFF  
STEP 1  
STEP 2  
LOCK-OUT  
G
TA  
STEP 3  
a48-8297  
STEP 5  
STEP 4  
a48-8298  
STEP 6  
STEP 7  
MODE  
Run Status  
Service Test  
Temperature  
Pressures  
Setpoints  
Inputs  
Alarm Status  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
STEP 8  
STEP 9  
STEP 10  
Fig. 2 — To Light Unit  
3
For your safety, keep the gas heating area clear and free of  
combustible materials, gasoline, and other flammable liquids  
and vapors.  
TO SHUT UNIT OFF  
To ensure proper functioning of the unit, flow of combus-  
tion and ventilating air must not be obstructed from reaching  
the gas heating area. Clearance of at least 4 ft on all sides is  
required.  
Do not turn off the electrical power to unit without first  
turning off the gas supply.  
Never attempt to manually light the main burners on a unit  
with a match, lighter, or any other flame.  
ROUTINE MAINTENANCE AND CARE  
FOR THE EQUIPMENT OWNER  
If the electric sparking device fails to light the main burn-  
ers, refer to the following shut off procedure, then call your  
dealer as soon as possible.  
Failure to follow these procedures can result in serious fire  
or personal injury.  
Before proceeding with those things you might want to  
maintain yourself, please carefully consider the following:  
See Fig. 1 for location of gas valve(s). Refer to Fig. 3 while  
proceeding with the following steps.  
1. Turn off the unit demand for cooling or heating by using  
the scrolling marquee. The scrolling marquee is located in  
the control box at the compressor end of the unit.  
1. TURN OFF GAS SUPPLY FIRST AND THEN  
ELECTRICAL POWER TO YOUR UNIT BEFORE  
SERVICING OR PERFORMING MAINTENANCE.  
2. Do not turn off electrical power to this unit without  
first turning off the gas supply.  
3. When opening access doors or performing mainte-  
nance functions inside your unit, be aware of sharp  
sheet metal parts and screws. Although special care  
has been taken to reduce sharp edges to a minimum,  
be extremely careful when handling parts or reaching  
into the unit.  
ESCAPE  
a. Push the  
is shown.  
key unit a blank display screen  
b. Push the  
lit.  
key until the SERVICE TEST LED is  
ENTER  
c. Push the  
STOP.  
key. The display will show  
key again. The NO/YES display  
key to toggle the display to  
Failure to follow these procedures can result in serious fire  
or personal injury.  
ENTER  
d. Push the  
will flash.  
e. Push the  
or  
Air Filters — Air filters should be checked at least every  
3 or 4 weeks and changed or cleaned whenever they become  
dirty. Table 1 indicates the correct filter size for your unit. Open  
the hinged filter access door to replace or inspect the filters. All  
units have filter tracks into which the filters slide. Remove the  
filters by pulling outward from the track. See Fig. 4 for filter  
access door location. Note the direction of flow arrows on the  
filter frame.  
ENTER  
YES and then push  
. The unit will be  
locked off from heating, cooling or any operation.  
The controls will still function and the display will  
still operate.  
2. Close the field-installed manual gas shutoff valve.  
3. Turn off the electrical power to the unit using the optional  
disconnect or the field-installed disconnect and lock off  
using proper lockout and tag-out procedures.  
If you have difficulty in locating your air filter in the return-  
air duct system, or if you have questions concerning proper  
filter maintenance, contact your dealer for instructions.  
4. Open the burner section hinged access door.  
Table 1 — Indoor-Air Filter Data*  
5. Move the switch on the gas valves to the OFF position  
and wait 5 minutes before doing any service in the section  
or on the piping.  
6. Close the burner section hinged access door.  
7. If unit is being shut down because of a malfunction, call  
your dealer as soon as possible.  
UNIT SIZE  
48Z  
QUANTITY...Size  
(in.)  
FILTER TYPE  
Disposable Fiberglass  
(Standard) or Medium Effi-  
ciency 30% Pleated (Optional)  
8...20 x 25 x 2,  
8...20 x 20 x 2  
030-050  
055-070  
90% Bag (Optional) with High- 6...20 x 24 x 22,  
Velocity Pre-Filters  
6...20 x 20 x 22,  
12...16 x 20 x 2,  
3...20 x 24 x 2  
If unit is being shut down because the heating season has  
ended, restore electrical power to the unit and reset the  
scrolling marquee to Run mode to ensure operation of the  
cooling system during the cooling season.  
Disposable Fiberglass  
(Standard) or Medium Effi-  
ciency 30% Pleated (Optional)  
12...20 x 25 x 2,  
12...20 x 25 x 2  
IMPORTANT: Should overheating occur or the gas supply  
fail to shut off, shut off the manual gas valve to the unit  
before shutting off the electrical supply.  
90% Bag (Optional) with High- 6...24 x 20 x 22,  
Velocity Pre-Filters  
6...24 x 24 x 22,  
6...20 x 24 x 2,  
6...24 x 24 x 2  
Do not use this unit if any part has been under water. Imme-  
diately call a qualified service technician to inspect the unit and  
to replace any part of the control system and gas control that  
has been under water.  
Disposable Fiberglass  
12...20 x 25 x 2,  
12...20 x 20 x 2  
(Standard) or Medium Effi-  
ciency 30% Pleated (Optional)  
075  
High Efficiency 65% Pleated  
(Optional)  
12...20 x 25 x 2,  
12...20 x 20 x 2  
Disposable Fiberglass  
MAINTAINING YOUR UNIT  
12...20 x 25 x 2,  
12...20 x 20 x 2  
(Standard) or Medium Effi-  
ciency 30% Pleated (Optional)  
090,105  
All maintenance should be handled by skilled, experienced  
personnel. Your dealer can help you establish a standard  
procedure.  
High Efficiency 65% Pleated  
(Optional)  
*See base unit Installation Instructions if field-supplied or optional  
factory-supplied filters are used. When replacing filters, always use  
the same type and size originally supplied.  
12...20 x 25 x 2,  
12...20 x 20 x 2  
4
When replacing your unit filters, always use the same size  
and type of filter that was originally supplied by the installer.  
Units with outdoor air capability have a cleanable filter for  
the outdoor air. This filter should be checked annually and  
cleaned as necessary. Remove by removing screws in outdoor-  
air filter retainer and sliding filters out of the unit.  
Heat Exchanger — To ensure dependable and efficient  
heating operation, the heat exchanger should be checked by a  
qualified maintenance person before each heating season, and  
cleaned when necessary. This checkout should not be attempt-  
ed by anyone not having the required expertise and equipment  
to do the job properly. Checking and/or cleaning the heat  
exchanger involves removing the gas controls assembly and  
the flue collector box cover and, when completed, reinstalling  
the gas controls assembly for proper operation. Also, the flue  
collector box cover must be replaced correctly so that a proper  
seal is maintained. Contact your dealer for the required period-  
ic maintenance.  
Never operate your unit without filters in place. Failure to  
heed this warning may result in damage to the blower  
motor and/or compressor. An accumulation of dust and lint  
on internal parts of your unit can cause loss of efficiency  
and, in some cases, fire.  
MAIN  
MODE  
Run Status  
Service Test  
Temperature  
ON  
Pressures  
Setpoints  
Alarm Status  
Inputs  
Outputs  
Configuration  
Time Clock  
Operating Modes  
Alarms  
ESCAPE ENTER  
OFF  
STEP 1  
STEP 2  
LOCK-OUT  
G
TA  
STEP 3  
STEP 5  
STEP 4  
STEP 7  
STEP 6  
Fig. 3 — To Shut Unit Off  
5
SIZES 030-050 (040 SHOWN)  
SIZES 055-070  
POWER EXHAUST VFD  
(NEAR SIDE)  
POWER EXHAUST  
CONTROL BOX  
(FAR SIDE)  
ACCESS DOOR  
ACCESS DOOR  
(FAR SIDE ONLY)  
FLUE OUTLETS  
(FAR SIDE)  
(NEAR SIDE ONLY)  
ACCESS DOOR  
(BOTH SIDES)  
ACCESS DOOR  
(FAR SIDE ONLY)  
CONTROL BOX  
GAS SECTION  
ACCESS DOOR  
(FAR SIDE)  
POWER EXHAUST ACCESS DOOR  
(BOTH SIDES)  
ACCESS DOOR  
(BOTH SIDES)  
FILTER  
ACCESS  
SIZES 075-105  
Fig. 4 — Door Locations (48Z Series Units)  
6
See Fig. 1 and 5 and proceed as follows to inspect the com-  
bustion area and power-venting system of your unit.  
1. Turn off gas supply and then electrical power to your unit.  
2. Open gas section access door.  
3. Using a flashlight, carefully inspect the burner areas for  
dirt, soot, rust, or scale.  
Fan and Belts — Periodically check the condition of fan  
wheels and housings and belt tension. When service is neces-  
sary, call your dealer.  
Evaporator-Fan Motor, Condenser-Fan Motor  
and Combustion-Fan Motor — Lubrication is not  
recommended. Bearings will not require lubrication for at least  
5 years of normal operation. After 5 years, motor life can be  
extended by having the motors serviced at an authorized motor  
service shop.  
If dirt, soot, rust, or scale accumulations are found, call  
your dealer and do not operate your heating section.  
Bodily injury or unit damage may result.  
Fan Shaft Bearings — Charge fittings annually with  
Shell Alvania No. 2 or equivalent grease.  
Evaporator and Condenser Coils — Cleaning of the  
coils should only be done by qualified service personnel.  
Contact your dealer for the required maintenance as needed.  
4. When you have completed your inspection, follow the  
start-up procedures in this manual to restore your unit to  
operation.  
5. Observe unit heating operation, and watch the burner  
flame core to see if it is bright blue. If you observe a sus-  
pected malfunction, or if the burner flame cores are not  
bright blue, call your dealer. See Fig. 6.  
Condensate Drain — The drain pan and condensate  
drain line should be checked and cleaned at the same time the  
cooling coils are checked by your dealer.  
Compressors — All compressors are factory shipped  
with a normal charge of the correct type refrigeration grade oil  
in them and should rarely require additional oil. The service  
technician must be certain the proper oil level is maintained in  
the compressor when it is installed and running.  
NOTE: Burner flame cores that have a mixture of orange,  
yellow, or red flames together with the blue may not be  
burning gas efficiently. Your dealer may have to adjust  
the air/gas mixture.  
6. Replace gas section access panel.  
Condenser Fan  
Unit Panels and Doors — After performing any main-  
tenance or service on the unit, be sure all panels and doors are  
securely fastened in place to prevent rain from entering  
unit cabinet and to prevent disruption of the correct unit airflow  
pattern.  
Do not poke sticks, screwdrivers, or any other object into  
revolving fan blades. Severe bodily injury may result.  
The fan must be kept free of all obstructions to ensure prop-  
er cooling. Contact your dealer for any required service.  
Electrical Controls and Wiring — Electrical controls  
are difficult to check without proper instrumentation; therefore,  
if there are any discrepancies in the operating cycle, contact  
your dealer and request service.  
Refrigerant Circuit — The refrigerant circuit is difficult  
to check for leaks without the proper equipment; therefore,  
if inadequate cooling is suspected, contact your dealer for  
service.  
Fig. 5 — Typical Location of Access Panel  
Combustion Area and Vent System — The com-  
bustion area and vent system should be visually inspected be-  
fore each heating season. The normal accumulation of dirt,  
soot, rust, and scale can result in loss of efficiency and improp-  
er performance if allowed to build up. Accumulation on the  
burner crossover tube can result in the burners firing out of nor-  
mal time sequence. This delayed ignition is characterized by an  
especially loud sound.  
If your unit makes an unusual or especially loud noise  
when the main burners are lit, shut down the heating  
section and call your dealer. Bodily injury or unit damage  
may result.  
Fig. 6 — Proper Flame Appearance  
7
REGULAR DEALER MAINTENANCE  
BEFORE YOU CALL FOR SERVICE, CHECK  
FOR SEVERAL EASILY SOLVED PROBLEMS  
In addition to the type of routine maintenance you might be  
willing to perform, your unit should be inspected regularly by a  
properly trained service technician. An inspection (preferably  
each year, but at least every other year) should include the  
following:  
1. Inspection of all flue product passages — including the  
burners, heat exchanger, flue collector box, and vent pipe.  
If insufficient heat or cooling is suspected:  
(
) Check for sufficient airflow. Check the air filters for dirt.  
Check for blocked return-air or supply-air grilles. Be sure they  
are open and unobstructed. Be sure heating and cooling set  
points are correct. If these checks do not reveal the cause, call  
your servicing dealer.  
2. Inspection of all combustion-air and ventilation-air pas-  
sages and openings.  
3. Close inspection of all gas pipes leading to and inside  
your unit.  
4. Adjustment of the air/gas mixture if the burner flames are  
not bright blue. (See Fig. 5 and 6 for location of access  
panel and proper flame appearance.)  
5. Inspection, and if required, cleaning of the condenser and  
evaporator coils.  
If your unit is not operating at all, check the following list for  
easy solutions:  
(
) Check to be sure that heating temperature set point is set  
above the indoor temperature during the heating season, or that  
cooling temperature set point is below the indoor temperature  
during the cooling season. Be sure the unit on/off switch is in  
the ON position and not in the OFF position. Be sure unit has  
been programmed with the appropriate time schedules and  
desired operating set points.  
(
) Is the electrical supply switch ON? Are any fuses blown,  
or have any of the circuit breakers tripped?  
) During the heating season, check the manual shutoff  
6. Inspection, and if required, cleaning of the evaporator  
drain pan.  
7. Inspection, cleaning, and lubrication of blower wheel  
housing and motor.  
8. Inspection of all supply-air and return-air ducts for leaks,  
obstructions, and insulation integrity. Any problems  
found should be resolved at this time.  
9. Inspection of the unit base to ensure that no cracks, gaps,  
etc., exist which may cause a hazardous condition.  
(
valve. Is this lever parallel with the pipe, indicating that the  
valve is open? Or is the lever at a right angle, indicating that  
the valve is closed? If closed, has the gas been shut off for  
safety reasons? Otherwise, you may open the valve and follow  
the start-up procedures listed in this manual.  
NOTE: Before proceeding with the next check, turn OFF the  
electrical power supply to the unit. Open the control access  
door.  
10. Inspection of the unit casing for signs of deterioration.  
11. Inspection of all electrical wiring and components to  
assure proper connection.  
12. Inspection for leaks in the refrigerant circuit. Pressure-  
check to determine appropriate refrigerant charge.  
(
) During the heating season, check the control switch on  
the gas valve. It is in the ON position? If it is not, be sure it has  
not been turned off for the purpose of safety. Follow the start-  
up procedures in this manual.  
(
) If your unit still fails to operate, call your servicing dealer  
13. Operational check of the unit to determine working con-  
ditions. Repair or adjustment should be made at this time.  
14. Your servicing dealer may offer an economical service  
contract that covers seasonal inspections. Ask for further  
details.  
Complete Service Instructions can be found in the base unit  
Controls, Start-Up, Operation, Service and Troubleshooting  
literature.  
for troubleshooting and repairs. Specify the model and serial  
numbers of your unit. (Record them in this manual in the space  
provided.) If the dealer knows exactly which unit you have, he  
may be able to offer suggestions over the phone, or save valu-  
able time through knowledgeable preparation for the service  
call.  
IN CASE OF TROUBLE  
If, after performing the above, unit performance is unsatis-  
factory, shut off the unit and call your dealer.  
Dealer’s Name _____________________________________  
Telephone No. _____________________________________  
Unit Model ________________________________________  
Unit Serial Number _________________________________  
Unit Address ______________________________________  
Bus Number _______________________________________  
Copyright 2007 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 04-53480045-01 Printed in U.S.A. Form 48Z-5SO Pg 8 7-07 Replaces: 48Z-3SO  
Book 1  
Tab 1a  

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